CN111705256A - System and method for preparing metal material by vacuum induction continuous casting high-throughput - Google Patents
System and method for preparing metal material by vacuum induction continuous casting high-throughput Download PDFInfo
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- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/34—Methods of heating
- C21D1/42—Induction heating
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- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/08—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of copper or alloys based thereon
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Abstract
The invention relates to a system and a method for preparing a metal material by vacuum induction continuous casting high-throughput. The method comprises the following steps: the method comprises the steps that bar materials placed on an automatic feeding device enter an electrode induction smelting coil under the control of a PLC (programmable logic controller) to be pre-smelted, a raw material crucible rotating to the lower part is fed according to the preset addition amount, a crucible placed on a platform enters the electromagnetic induction smelting coil under the action of a crucible lifting mechanism to be refined, alloyed and subjected to subsequent heat treatment, and after the crucible finishes alloy configuration and smelting, a batch of multi-component, multi-scale and light-weight ingots under the same experimental condition can be obtained, so that high-flux preparation of metal material samples is realized. The device has convenient working procedures and simple structure, realizes multiple working procedures such as quantitative master batch preparation, smelting, alloying and the like on the same equipment, is operated continuously, and can continuously cast metal samples with high flux.
Description
Technical Field
The invention belongs to the field of metal material preparation, and relates to a novel device and a novel technology for preparing a metal material through high-flux continuous smelting. The device and the technology can rapidly prepare a large amount of metal alloy materials with different alloy components in a very short time; meanwhile, the metal material prepared by the device and the technology can meet the requirements of subsequent hot working, heat treatment and performance detection in both size and quality.
Background
The main direction for developing new metal materials is the design and optimization of the composition. The microalloying technology for greatly improving the material performance by matching a small amount of alloy elements can not obviously improve the material performance and the cost of raw materials and processes, and is a preferred technology for developing novel metal materials. The research and development of new materials always follow the research and development mode of iterative cycle and trial and error, the technical process that one component needs to pass through the whole flow is changed, the research and development input period is long, the cost is high, and the development and the application of the new materials are seriously restricted. Therefore, the research and development mode of innovative materials is imperative to accelerate the progress of the materials from research to application. The genetic engineering of materials provides a revolutionary new material research and development mode.
The 'material genetic engineering' plan takes big data as support, adopts high-throughput design, preparation and characterization technology, and promotes the material research to turn from the traditional trial and error mode to a new mode with low cost and quick response, thereby accelerating the research and development speed of new materials and realizing the aim of 'double halving' of research and development cost and period.
"material high throughput preparation" refers to the preparation of large numbers of samples in a short time in anticipation of converting the iterative trial and error of traditional material studies into parallel processing study modes, with quantitative variations leading to qualitative variations in efficiency. Through research and development for nearly 10 years, technologies such as a diffusion multivariate method, a jet printing synthesis method, selective laser cladding, magnetron sputtering and the like are also widely applied to high-throughput preparation of two-dimensional metal materials (such as films and coatings).
The recently published Chinese patent CN109211655 discloses a system and a method for continuously and rapidly preparing alloy samples with high flux, the device is provided with an automatic batching system, a sampling system, a continuous rotating system and a heating and smelting device, a semi-closed continuous smelting technology is constructed based on the four systems, the high-efficiency preparation of alloy materials such as Al, Mg and the like is realized, and the mass of a single sample is less than or equal to 100 g. The Chinese patent CN105903931 discloses a high-throughput preparation device and method for array type block amorphous alloy, which describe the device and the technical method in detail, solve the problem that the traditional device can only prepare one sample at a time, and can prepare more than 10 amorphous block materials simultaneously, thereby greatly reducing the preparation cost of the amorphous alloy and improving the preparation efficiency of the amorphous alloy.
The preparation process of the metal material generally comprises fusion casting-forging-rolling-heat treatment-performance analysis, and a prepared sample needs to have a certain size to be processed. Fusion casting is the first step in the preparation of metallic materials, the degree of cleanliness and homogenization of which directly determines the later thermomechanical working, heat treatment and material properties of the steel. Clean smelting is a precondition for improving the performance of metal materials. Alloy steel, high-temperature alloy, titanium alloy and other metal materials are required to be smelted in a high vacuum atmosphere and the oxygen content is strictly controlled. Although the vacuum smelting technology is mature, how to realize high-throughput preparation under a vacuum atmosphere faces huge computational and equipment challenges, and relevant reports are not found. In particular, the material properties of the smelted metal ingot can be obtained through hot working and heat treatment such as forging and rolling, so that a single sample has to have certain large mass and size to realize forging and rolling. How to realize high-throughput preparation of large-size samples is a difficult problem faced by devices and techniques.
Disclosure of Invention
The invention provides a system and a technology for preparing a metal material by vacuum induction continuous casting at high flux, which realize high flux preparation of materials with different microalloy components by electrode induction melting, casting of a high flux rotary crucible, alloying refining and induction heating heat treatment. All melting, pouring and heat treatment can be completed in the vacuum chamber, and the control and the cleaning of the oxygen content in the metal material are ensured.
The technical scheme of the invention is as follows: a system for preparing metal materials by vacuum induction continuous casting high-throughput comprises an automatic feeding device, a heating and smelting device, a multi-crucible experiment platform, a vacuum and atmosphere device and a PLC control device.
The automatic feeding device is used for realizing automatic quantitative addition of the master batch.
The heating and smelting device is used for melting, alloying refining and induction heating heat treatment of the master batch.
The multi-crucible experiment platform is used for pouring of a high-flux rotary crucible.
The vacuum and atmosphere device is used for constructing an experimental environment meeting the requirements of vacuum and inert atmosphere protection.
And the PLC control device is used for controlling the cooperative operation of the automatic feeding device, the heating and smelting device, the multi-crucible experiment platform and the vacuum and atmosphere system.
Further, the automatic feeding device comprises a rotating motor, a lifting motor, a translation guide rail, a moving platform, a support frame, a material replenishment operation bin, a master batch supply rod and a weight sensor, wherein the support frame is arranged at the upper part of the material replenishment operation bin, the material replenishment operation bin is arranged at the upper part of the smelting system, and the three are in sealing connection; the translation guide rail is vertically erected in the support frame, the guide rail is connected with the moving platform, and the stepping motor is arranged on the moving platform; the moving platform is connected with the master batch supply rod, and the weight sensor is arranged at the bottom end of the master batch supply rod.
Furthermore, the heating smelting device comprises a smelting chamber, an electrode induction smelting device, an electromagnetic induction heating system and a high-frequency power supply. The electrode induction smelting device and the electromagnetic induction heating system are arranged in the smelting chamber and are connected with a high-frequency power supply arranged outside the smelting chamber; the smelting chamber is hermetically connected with the lower part of the material supply operation bin; an opening and an observation window which are connected with a vacuum system are arranged on the side of the smelting chamber; and a hand hole window is arranged above the smelting chamber.
Because of the principle of induction heating, the metal self-body heating is adopted instead of radiation heating, so compared with a heating mode of a resistance wire/thermocouple, the invention can reduce the phenomenon of mutual interference of the temperatures of different smelting systems, is favorable for accurately controlling the temperature, and further ensures the smelting quality of the metal
Furthermore, the multi-crucible experimental platform comprises a rotating motor, a rotating shaft, a circular multi-crucible platform, a crucible and a crucible station, wherein the center of the circular multi-crucible platform is arranged below the electrode induction smelting device, is arranged in the smelting chamber and is in sealed connection with the rotating shaft, the rotating shaft is connected with a stepping motor, and the crucible is arranged on the crucible station; the crucible stations surround the multi-crucible platform, and the number of the crucible stations is not less than 4.
The smelting chamber and the multi-crucible platform are made of 304 stainless steel, the smelting chamber is a double-layer water-cooling vacuum chamber, and a crucible station of the multi-crucible platform is provided with a high-temperature-resistant ceramic clamping position.
Further, the vacuum & atmosphere system comprises a two-stage vacuum unit: air-cooled composite molecular pump, direct-connected mechanical pump, air inlet and outlet. The two-stage vacuum unit is arranged outside the smelting chamber, and the air inlet and the air outlet are arranged on two sides of the material supply operation bin.
The heating and smelting device comprises a smelting chamber, a material rod, a heating and smelting unit and a high-frequency power supply;
the material rod is vertically arranged in the material supply operation bin; the upper part of the material rod is connected with a weight sensor on the master batch supply rod 105;
the heating and smelting unit is arranged in the smelting chamber and is connected with a high-frequency power supply 202 arranged outside the smelting chamber;
the smelting chamber is hermetically connected with the lower part of the material supply operation bin.
The heating and smelting unit comprises an electrode induction smelting device and an electromagnetic induction heating device;
the electromagnetic induction heating device comprises a lifting motor, a crucible lifting rod, a crucible tray and an electromagnetic induction heating coil;
the electrode induction smelting device is an electrode induction smelting coil;
the lifting motor is arranged at the lower part of the crucible lifting rod and is connected with the crucible lifting rod; the top of the crucible lifting rod is connected with the crucible tray; the electromagnetic heating coil is arranged above the multi-crucible platform; the crucible lifting rod, the crucible and the electromagnetic induction heating coil are coaxial, the number of the electromagnetic heating coils is not less than 1,
the multi-crucible platform and the crucible lifting rod are in an interlocking design, so that the rotation action of the experiment platform and the lifting action of the crucible are interlocked, and equipment damage is avoided.
Furthermore, the electrode induction melting coil of the melting system is spiral, and the diameter D of the top of the coilx1Bottom diameter of Dx2The electromagnetic induction heating coil is cylindrical, and the diameter of the coil is Dx 3.
Further, the diameter D of the material rodb<Dx1The length of the bar is 50 mm-800 mm. The diameter D of the crucibleg<Dx3。
Furthermore, the experimental equipment is controlled by a PLC (programmable logic controller), so that accurate action, higher automation level and good human-computer interface are ensured, and metering and detecting instruments such as a vacuum gauge, a pressure gauge, a flow meter and the like are configured.
Another object of the present invention is to provide a method for using the above apparatus, which specifically comprises the following steps:
s1) placing the micro-alloy powder with the designed proportion in a certain amount of crucibles according to the experiment requirement, numbering the crucibles and fixing the crucibles on the stations of the multi-crucible platform respectively.
S2) controlling a vacuum unit, an air-cooled composite molecular pump and a direct-connected mechanical pump through a PLC (programmable logic controller) according to designed experimental conditions, and communicating an air inlet and an air outlet with a high-pressure argon bottle to realize vacuum and atmosphere environment inside an experimental cavity.
S3) controlled by a PLC control device, the multi-crucible platform rotates anticlockwise, so that the prepared crucibles sequentially rotate to the lower part of the electrode induction melting device, and meanwhile, the master batch supply rod rotates and moves downwards, so that the top end of the material rod held on the rod enters an electrode induction melting coil.
S4) controlling power supply power by a PLC control device, electrifying the electrode induction melting coil, melting the material rod into liquid, converging the liquid to the conical tip position of the base metal, gradually forming liquid flow along with the convergence of the liquid metal, and flowing the liquid flow to the crucible, wherein the molten steel has certain impact to mix and dissolve the molten steel and the microalloy elements due to the height difference between the coil and the crucible. And the quantitative control of the master batch is completed through the feedback of the weighing sensor.
S5) after the electrode induction melting device finishes the quantitative allocation of the master batch, the PLC control device controls the electromagnetic induction heating system again, the crucible lifting rod finishes the lifting action under the instruction, and all crucibles on the platform are conveyed into the electromagnetic induction heating coil.
S6) controlling power supply power through a PLC control device, electrifying an electromagnetic induction heating coil, starting alloy smelting, obtaining experimental ingots after the smelting is finished, thus obtaining a batch of multi-component and light-weight ingots under the same experimental conditions, reheating through the electromagnetic induction heating coil according to experimental requirements, carrying out heat treatment processes such as homogenization and the like, and achieving the purpose of high-flux preparation of metal material samples.
The electrode induction smelting device is designed based on an EIGA system, based on a vertically-oriented rotary electrode material rod, and through the control of a specially-designed spiral induction coil, the electrode material rod is continuously melted in an inert gas environment without a ceramic crucible, so that the smelting of metal raw materials is realized. The electromagnetic induction heating system is based on the electromagnetic induction heating principle, namely alternating current generates induced current in a conductor so as to cause the conductor metal to generate heat, and meanwhile, alternating magnetic field generated by the alternating current in the conductor generates electromagnetic stirring force to stir molten metal so as to realize the refining of alloying. Electrode induction pre-smelting is carried out on the master batch, formed metal liquid flows into the crucible and is mixed with alloy element powder in the crucible in advance, and then the alloy ingot is prepared through electromagnetic induction alloying refining.
Compared with the prior art, the invention has the positive improvement effects that:
the method can realize efficient batch preparation of alloy cast ingots with various components, and obviously improves the preparation efficiency of samples;
the method can simulate the smelting situation, realize the batching, the pre-smelting quantitative feeding, the refining alloying, the solidification ingot forming, and continuously and rapidly prepare the alloy sample with high flux; the device has high degree of mechanization, novelty, high efficiency, strong controllability and high safety;
and thirdly, the two smelting systems can be used cooperatively and can be operated independently, so that the selectivity of practical application is increased.
And fourthly, the multi-crucible platform can increase the number of samples in a single batch by increasing the number of crucible stations.
And fifthly, due to the existence of the plurality of electromagnetic heating coils, a plurality of samples can be refined and heat-treated at one time, and the high-flux smelting alloying and heat treatment process is realized.
The monomer sample prepared by the method has strong size controllability, so that a small sample can be prepared, compared with an alloy sample prepared by the traditional single-furnace smelting, the material consumption is controllable, the consumption is obviously reduced, and more than 500g of sample can be prepared for subsequent thermo-mechanical treatment and performance research.
Drawings
FIG. 1 is a front view of a vacuum induction continuous casting high-throughput metal material manufacturing system according to the present invention.
Fig. 2 is a side view of a vacuum induction continuous casting high-throughput metal material manufacturing system according to the present invention.
FIG. 3 is a top view of a vacuum induction continuous casting high-throughput metal material manufacturing system according to the present invention.
FIG. 4 is a schematic structural diagram of an automatic feeding system of a vacuum induction continuous casting high-flux metal material preparation system.
FIG. 5 is a schematic structural diagram and a schematic diagram of an electrode induction melting device of a system for preparing a metal material by vacuum induction continuous casting and high flux.
FIG. 6 is a schematic structural diagram of an electromagnetic induction melting system of the system and the method for preparing metal materials by vacuum induction continuous casting and high flux.
FIG. 7 is a photograph of an ingot of CNS I steel of different alloy compositions obtained in embodiment 1.
FIG. 8 is a photograph of an ingot of CNS I steel of different alloy compositions obtained in embodiment 2.
Fig. 9 is a photograph of an ingot of CrZrCu obtained in embodiment 3.
In the figure:
1-automatic feeding device, 101-stepping motor, 1011-rotating motor, 1012-lifting motor, 102-translation guide rail, 103-support frame, 104-material supply operation cabin, 105-master batch supply rod, 106-weight sensor, 107-mobile platform; 2-heating smelting device, 201-smelting chamber, 202-high frequency power supply, 203-material bar, 204-observation window, 205-hand hole window; 3-a multi-crucible experiment platform, 301-a stepping motor rotating motor, 302-a rotating shaft, 303-a multi-crucible platform, 304-a crucible and 305-a crucible station; 4-vacuum and atmosphere device 4, 401-composite molecular pump, 402-mechanical pump, 403-air inlet and outlet; 5-electrode induction melting device, 501-bar stock, 502-electrode induction coil; 6-an electromagnetic induction heating device, 601-a stepping motor lifting motor, 602-a crucible lifting rod, 603-a crucible tray, 604-an electromagnetic induction heating coil; 7-PLC control device.
Detailed Description
In order to make the technical problems, technical solutions and advantages of the present invention more apparent, the following detailed description is given with reference to the accompanying drawings and specific embodiments.
As shown in fig. 1-3, the system for preparing metal material by vacuum induction continuous casting high flux of the invention comprises an automatic feeding device 1, a heating and melting device 2, a multi-crucible experimental platform 3, a vacuum and atmosphere device 4 and a PLC control device 7;
the automatic feeding device 1 is used for realizing automatic quantitative addition of the master batch;
the heating and smelting device 2 is used for melting, alloying refining and induction heating heat treatment of the master batch;
the multi-crucible experiment platform 3 is used for casting a high-flux rotary crucible;
the vacuum and atmosphere device 4 is used for constructing an experimental environment meeting the requirements of vacuum and inert atmosphere protection;
and the PLC control device 7 is used for controlling the cooperative operation of the automatic feeding device, the heating and smelting device, the multi-crucible experiment platform and the vacuum and atmosphere device.
The automatic feeding device 1 comprises a rotating motor 1011, a lifting motor 1012, a translation guide rail 102, a moving platform 107, a support frame 103, a material replenishing operation cabin 104, a master batch supply rod 105 and a weight sensor 106;
wherein the support frame 103 is arranged at the upper part of a material supply operation bin 104, and the material supply operation bin 104 is arranged at the upper part of the smelting system 2;
the translation guide rail 102 is arranged inside the support frame 103, one end of the translation guide rail 102 is connected with the moving platform 107, and the rotation 1011 and the lifting motor 1012 are both arranged on the moving platform 107; the moving platform 107 is connected to the master batch supply rod 105, and the weight sensor 106 is disposed at the bottom end of the master batch supply rod 105, as shown in fig. 4.
A system-connected opening and viewing window 203; a hand hole window 204 is arranged above the smelting chamber.
The multi-crucible experiment platform 3 comprises a rotating motor 301, a rotating shaft 302, a circular multi-crucible platform 303, a crucible 304 and a crucible station 305;
the center of the circular multi-crucible platform 303 is arranged in the smelting chamber 201 below the electrode induction smelting device 5 and is in transmission connection with the rotating shaft 302; the rotating shaft 302 is connected with a rotating motor 301;
the crucible 304 is placed on a crucible station 305; the crucible station 305 surrounds the multi-crucible platform 303.
The number of the crucible stations 305 is not less than 4;
the smelting chamber 201 and the multi-crucible platform 303 are made of 304 materials, the smelting chamber 20 is a double-layer water-cooling vacuum chamber, and a crucible station 305 of the multi-crucible platform 303 is provided with a high-temperature-resistant ceramic clamping position.
The vacuum and atmosphere device 4 comprises a first-stage vacuum unit and a second-stage vacuum unit;
the first-stage vacuum unit and the second-stage vacuum unit are both arranged outside the smelting chamber 201, and the air inlet and outlet 403 are arranged on two sides of the material supply operation bin 104;
the first-stage vacuum unit and the second-stage vacuum unit are composed of an air-cooled composite molecular pump 401 and a direct-connected mechanical pump 402, the air-cooled composite molecular pump 401 and the direct-connected mechanical pump 402 are communicated with the smelting chamber 201 through pipelines, and the air inlet and outlet 403 are arranged on two sides of a material supply operation bin.
The heating smelting device 2 comprises a smelting chamber 201, a material rod 203, a heating smelting unit and a high-frequency power supply 202;
the material rod 203 is vertically arranged in the material supply operation bin 104; the upper part of the material rod 203 is connected with a weight sensor 106 on the master batch supply rod 105;
the heating and smelting unit is arranged inside the smelting chamber 201 and is connected with a high-frequency power supply 202 arranged outside the smelting chamber 201;
the smelting chamber 201 is hermetically connected with the lower part of the material supply operation bin 104; an opening and an observation window 204 connected with a vacuum system are arranged on the side of the smelting chamber 201; a hand hole window 205 is arranged above the smelting chamber.
The heating and smelting unit comprises an electrode induction smelting device 5 and an electromagnetic induction heating device 6;
the electromagnetic induction heating device 6 comprises a lifting motor 601, a crucible lifting rod 602, a crucible tray 603 and an electromagnetic induction heating coil 604;
the electrode induction melting device 5 is an electrode induction melting coil 502;
wherein, the lifting motor 601 is arranged at the lower part of the crucible lifting rod 602 and is connected with the crucible lifting rod 602; the top of the crucible lifting rod 602 is connected with a crucible tray 603; the electromagnetic heating coil 604 is arranged above the multi-crucible platform 303; the crucible lifting rod 602, the crucible 304 and the electromagnetic induction heating coil 604 are coaxial, and the number of the electromagnetic heating coils 604 is not less than 1, as shown in fig. 6.
The method for preparing the metal material by the system casting high-flux method for preparing the metal material by vacuum induction continuous casting high-flux specifically comprises the following steps:
s1) putting microalloy powder with a designed proportion in a certain amount of crucibles 304 according to experimental requirements, numbering the crucibles 304 and fixing the crucibles 304 on the stations 305 of the multi-crucible platform 303 respectively;
s2) controlling a vacuum unit, an air-cooled composite molecular pump 401, a direct-connected mechanical pump 402 and a high-pressure argon bottle communicating an air inlet and outlet 403 through a PLC (programmable logic controller) 7 according to designed experimental conditions to realize vacuum and atmosphere environment in an experimental cavity;
s3) is controlled by the PLC control device 7 to rotate counterclockwise on the multi-crucible platform 303, so that the prepared crucibles 304 are sequentially rotated to the lower part of the electrode induction melting device 5, and at the same time, the master batch supply rod 105 is rotated and moved downward, so that the top end of the material rod 501 held on the rod enters the electrode induction melting coil 502;
s4) controlling the power of the power supply 202 through the PLC control device 7, electrifying the electrode induction melting coil 502, melting the material rod 501 into liquid, converging the liquid to the conical tip position of the base metal, gradually forming liquid flow along with the convergence of the liquid metal, flowing to the crucible 304, and mixing the molten steel and the micro-alloy elements in the crucible 304. The quantitative control of the master batch is completed through the feedback of the weight sensor 106;
s5) after the electrode induction melting device 5 finishes the quantitative allocation of the master batch, the PLC control device 7 controls the electromagnetic induction heating device 6 again, the crucible lifting rod 602 finishes the lifting action under the instruction, and the crucible 304 on the platform is completely sent into the electromagnetic induction heating coil 604;
s6) controlling the power of the power supply 202 through the PLC control device 7, electrifying the electromagnetic induction heating coil 604, starting the smelting of the alloy, obtaining experimental ingots after the smelting is finished, thus obtaining a batch of multi-component and light-weight ingots under the same experimental conditions, reheating through the electromagnetic induction heating coil according to the experimental requirements, carrying out a homogenization heat treatment process, and achieving the high-flux preparation of the metal material sample.
The electrode induction melting coil 502 of the melting system is spiral, and the diameter D of the top of the coilx1Bottom diameter of Dx2The electromagnetic induction heating coil 604 is cylindrical and has a diameter Dx3。
The diameter D of the charge bar 501b<Dx1The length of the bar is 50 mm-800 mm; the diameter D of the crucible 304g<Dx3。
Example 1:
the CNS I steel prepared by the equipment and the method comprises the following components in percentage by mass: c: 0.08%, Cr: 9.0%, Mn: 0.45%, W: 2.1%, N: 0.05%, Ta: 0.10%, Ti 0.5%, Si: 0.1%, V: 0.5%, B < 0.001%, S < 0.003%, P < 0.005%, and the balance Fe.
The specific preparation process comprises the following steps:
10 crucibles 304 are numbered and fixed to stations 305 of the multi-crucible platform 303, respectively. According to the designed experimental conditions, the vacuum unit, the air-cooled composite molecular pump 401, the direct-connected mechanical pump 402 and the high-pressure argon bottle communicating the air inlet and outlet 403 are controlled by the PLC control device 7, so that the vacuum and atmosphere environment in the experimental cavity is realized, and the vacuum degree is maintained at about 1 Pa. The numbered crucibles 304 are sequentially rotated below the electrode induction melting device 5 by the counterclockwise rotation of the multi-crucible platform 303 by the control of the PLC control device 7, and at the same time, the master batch feed rod 105 is rotated and moved down, so that the tip of the rod 501 held by the rod enters the electrode induction melting coil 502. The power of the power supply 202 was controlled by the PLC controller 7 so as to be maintained at 6Kw, and when the electrode induction melting coil 502 was energized, the material rod 501 began to melt into a liquid state and converged to the base material taper position, and a liquid flow was gradually formed with the convergence of the liquid metal and flowed into the crucible 304, and the molten steel was solidified in the crucible 304. Through the feedback of the weight sensor 106, the quantitative control of the master batch is completed, so that the weight of the molten steel in each crucible 304 is 50 g. After the electrode induction melting device 5 finishes the quantitative allocation of the master batch, the PLC control device 7 switches off the circuit of the electrode induction melting device 5, switches on the circuit of the electromagnetic induction heating device 6 after the crucible 304 lifting rod 602 finishes the lifting action under the instruction, and sends all 10 crucibles 304 on the platform into the electromagnetic induction heating coil 604 for heating. The power of the high-frequency power supply 202 was controlled by the PLC control device 7 to be maintained at 4Kw, and the alloy in the crucible 304 was started to be vacuum-melted for the second time. After the smelting is finished, 10 ingots of the crucibles 304 are taken out in sequence, so that a batch of 10 CNS I steel ingots with the weight of 50g can be obtained under the same experimental conditions, and a basic sample is provided for a subsequent parallel comparison test.
Example 2
The CNS I steel with various microalloy components prepared by the equipment and the method comprises the following raw material components in percentage by mass: c: 0.09%, Cr: 9.0%, W: 2.0%, N: 0.05%, B < 0.001%, S < 0.003%, P < 0.005%, and the balance Fe; into 5 different crucibles 304, 100mg of Ta, 100mg of Si, 450mg of Mn, 500mg of Ti and 500mg of V were placed, respectively.
The specific preparation process comprises the following steps:
the 5 crucibles 304 are numbered and fixed in respective stations 305 of the multi-crucible platform 303. According to the designed experimental conditions, the vacuum unit, the air-cooled composite molecular pump 401, the direct-connected mechanical pump 402 and the high-pressure argon bottle communicating the air inlet and outlet 403 are controlled by the PLC control device 7, so that the vacuum and atmosphere environment in the experimental cavity is realized, and the vacuum degree is maintained at about 0.1 Pa. The numbered crucibles 304 are sequentially rotated below the electrode induction melting device 5 by the counterclockwise rotation of the multi-crucible platform 303 by the control of the PLC control device 7, and at the same time, the master batch feed rod 105 is rotated and moved down, so that the tip of the rod 501 held by the rod enters the electrode induction melting coil 502. The power of the power supply 202 is controlled by the PLC controller 7 to be maintained at 8Kw, and when the electrode induction melting coil 502 is energized, the material rod 501 starts to melt into a liquid state and collects at the base material taper position, and a liquid flow is gradually formed with the collection of the liquid metal and flows into the crucible 304, and the molten steel is solidified in the crucible 304. Through the feedback of the weight sensor 106, the quantitative control of the master batch is completed, so that the weight of the molten steel in each crucible 304 is 100 g. After the electrode induction melting device 5 finishes the quantitative allocation of the master batch, the PLC control device 7 switches off the circuit of the electrode induction melting device 5, switches on the circuit of the electromagnetic induction heating device 6 after the crucible 304 lifting rod 602 finishes the lifting action under the instruction, and sends all 5 crucibles 304 on the platform into the electromagnetic induction heating coil 604 for heating. The power of the high-frequency power supply 202 was controlled by the PLC control device 7 to be maintained at 6Kw, and the alloy in the crucible 304 was started to be vacuum-melted for the second time. After the smelting is finished, the cast ingots of 5 crucibles 304 are taken out in sequence, so that a batch of CNSI steel ingots with different microalloy components and the weight of 5 CNSI steel ingots with different microalloy components of about 100g can be obtained under the same experimental conditions, and the CNSI steel ingots are used for subsequent research on the structure and the performance of CNS I microalloying.
Example 3
The CrZrCu with various microalloy components prepared by the equipment and the method comprises the following raw material components in percentage by mass: and Fe: 0.03%, Zn: < 0.0005%, Pb: < 0.0005%, Sn: < 0.0005%, Cu: 99 percent. Placing Cr and Zr powder into 9 different crucibles 304 respectively according to orthogonal experiments, wherein the crucibles 304 with the specific weights of No. 1-3 are 800mg Cr, 100mg Zr, 800mg Cr, 90mg Zr, 800mg Cr and 80mg Zr; crucible No. 4-6 is 700mg Cr, 100mg Zr, 800mg Cr, 90mg Zr, 800mg Cr, 80mg Zr; crucible No. 7-9 was 600mg Cr, 100mg Zr, 800mg Cr, 90mg Zr, 800mg Cr, 80mg Zr.
The specific preparation process comprises the following steps:
9 crucibles 304 are numbered and fixed to stations 305 of the multi-crucible platform 303, respectively. According to the designed experimental conditions, the vacuum unit, the air-cooled composite molecular pump 401, the direct-connected mechanical pump 402 and the high-pressure argon bottle communicating the air inlet and outlet 403 are controlled by the PLC control device 7, so that the vacuum and atmosphere environment in the experimental cavity is realized, and the vacuum degree is maintained at about 0.1 Pa. The numbered crucibles 304 are sequentially rotated below the electrode induction melting device 5 by the counterclockwise rotation of the multi-crucible platform 303 by the control of the PLC control device 7, and at the same time, the master batch feed rod 105 is rotated and moved down, so that the tip of the rod 501 held by the rod enters the electrode induction melting coil 502. The power of the power supply 202 is controlled by the PLC controller 7 to be maintained at 5Kw, and when the electrode induction melting coil 502 is energized, the material rod 501 starts to melt into a liquid state and collects at the base material taper position, and a liquid flow is gradually formed with the collection of the liquid metal and flows into the crucible 304, and the molten steel is solidified in the crucible 304. Through the feedback of the weight sensor 106, the quantitative control of the master batch is completed, so that the weight of the molten steel in each crucible 304 is 100 g. After the electrode induction melting device 5 finishes the quantitative allocation of the master batch, the PLC control device 7 switches off the circuit of the electrode induction melting device 5, switches on the circuit of the electromagnetic induction heating device 6 after the crucible 304 lifting rod 602 finishes the lifting action under the instruction, and sends all 9 crucibles 304 on the platform into the electromagnetic induction heating coil 604 for heating. The power of the power supply 202 was controlled by the PLC control device 7 to be maintained at 4Kw, and the alloy in the crucible 304 was started to be vacuum-melted for the second time. After the smelting is finished, the 9 ingots of the crucibles 304 are taken out in sequence, so that a batch of CNS I steel ingots with different microalloy components and the weight of about 100g under the same experimental condition can be obtained, and the subsequent research on the structure and the performance of the CNS I microalloyed steel ingots is realized.
The system and the method for preparing the metal material by vacuum induction continuous casting and high throughput provided by the embodiment of the application are described in detail above. The above description of the embodiments is only for the purpose of helping to understand the method of the present application and its core ideas; meanwhile, for a person skilled in the art, according to the idea of the present application, there may be variations in the specific embodiments and the application scope, and in summary, the content of the present specification should not be construed as a limitation to the present application.
As used in the specification and claims, certain terms are used to refer to particular components. As one skilled in the art will appreciate, manufacturers may refer to a component by different names. This specification and claims do not intend to distinguish between components that differ in name but not function. In the following description and in the claims, the terms "include" and "comprise" are used in an open-ended fashion, and thus should be interpreted to mean "include, but not limited to. "substantially" means within an acceptable error range, and a person skilled in the art can solve the technical problem within a certain error range to substantially achieve the technical effect. The description which follows is a preferred embodiment of the present application, but is made for the purpose of illustrating the general principles of the application and not for the purpose of limiting the scope of the application. The protection scope of the present application shall be subject to the definitions of the appended claims.
It is also noted that the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a good or system that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such good or system. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other like elements in a commodity or system that includes the element.
It should be understood that the term "and/or" as used herein is merely one type of association that describes an associated object, meaning that three relationships may exist, e.g., a and/or B may mean: a exists alone, A and B exist simultaneously, and B exists alone. In addition, the character "/" herein generally indicates that the former and latter related objects are in an "or" relationship.
The foregoing description shows and describes several preferred embodiments of the present application, but as aforementioned, it is to be understood that the application is not limited to the forms disclosed herein, but is not to be construed as excluding other embodiments and is capable of use in various other combinations, modifications, and environments and is capable of changes within the scope of the application as described herein, commensurate with the above teachings, or the skill or knowledge of the relevant art. And that modifications and variations may be effected by those skilled in the art without departing from the spirit and scope of the application, which is to be protected by the claims appended hereto.
Claims (10)
1. A system for preparing metal materials by vacuum induction continuous casting high-throughput is characterized by comprising an automatic feeding device, a heating and smelting device, a multi-crucible experiment platform, a vacuum and atmosphere device and a PLC (programmable logic controller) control device;
the automatic feeding device is used for realizing automatic quantitative addition of the master batch;
the heating and smelting device is used for melting, alloying and refining of the master batch and induction heating heat treatment;
the multi-crucible experiment platform is used for casting the high-flux rotary crucible;
the vacuum and atmosphere device is used for constructing an experimental environment meeting the protection of vacuum and inert atmosphere;
and the PLC control device is used for controlling the cooperative operation of the automatic feeding device, the heating and smelting device, the multi-crucible experiment platform and the vacuum and atmosphere device.
2. The system of claim 1, wherein the automatic feeding device comprises a rotating motor, a lifting motor, a translation guide rail, a moving platform, a support frame, a material replenishment operating cabin, a master batch supply rod and a weight sensor;
the supporting frame is arranged above a material supply operation bin, and the material supply operation bin is arranged above the smelting system;
the translation guide rail is arranged in the support frame, one end of the translation guide rail is connected with the moving platform, and the rotating motor and the lifting motor are both arranged on the moving platform; the mobile platform is connected with the master batch supply rod, and the weight sensor is arranged at the bottom end of the master batch supply rod.
3. The system of claim 2, wherein the heating and melting device comprises a material bar, a melting chamber, a heating and melting unit and a high-frequency power supply;
the material rod is placed in the material supply operation bin; the upper part of the material rod is connected with a weight sensor on the master batch supply rod;
the heating and smelting unit is arranged in the smelting chamber and is connected with a high-frequency power supply arranged outside the smelting chamber;
the smelting chamber is hermetically connected with the lower part of the material supply operation bin.
4. The system of claim 3, wherein the multi-crucible experimental platform comprises a rotary motor, a rotating shaft, a circular multi-crucible platform, a crucible and a crucible station;
the center of the circular multi-crucible platform is arranged in the smelting chamber below the electrode induction smelting device and is in transmission connection with a rotating shaft; the rotating shaft is connected with a rotating motor;
the crucible is arranged on a crucible station; the plurality of crucible station rings are arranged on the multi-crucible platform.
5. The system of claim 4, wherein the number of crucible stations is no less than 4;
the melting chamber and the multi-crucible platform are made of 304 stainless steel, the melting chamber is a double-layer water-cooling vacuum chamber, and a crucible station of the multi-crucible platform is provided with a high-temperature-resistant ceramic clamping position.
6. The system of claim 4, wherein the vacuum and atmosphere device comprises a first stage vacuum unit, a second stage vacuum unit, and an intake and exhaust port:
the first-stage vacuum unit and the second-stage vacuum unit are arranged outside the smelting chamber, and the air inlet and the air outlet are arranged on two sides of the material supply operation bin;
and the first-stage vacuum unit and the second-stage vacuum unit are respectively composed of an air-cooled composite molecular pump and a direct-connected mechanical pump.
7. The system of claim 3, wherein the heat smelting unit comprises an electrode induction smelting unit and an electromagnetic induction heating unit;
the electromagnetic induction heating system comprises a lifting motor, a crucible lifting rod, a crucible tray and an electromagnetic induction heating coil;
the electrode induction smelting device is an electrode induction smelting coil;
the lifting motor is arranged at the lower part of the crucible lifting rod and is connected with the crucible lifting rod; the top of the crucible lifting rod is connected with the crucible tray; the electrode induction melting coil is arranged between the lower part of the material rod and the upper part of the multi-crucible platform; the crucible lifting rod, the crucible and the electromagnetic induction heating coil are coaxial, and the number of the electromagnetic heating coils is not less than 1.
8. Use of a system according to any of claims 1-7, characterized in that it comprises in particular the following steps:
s1) placing the microalloy powder in a crucible according to the experiment requirement, numbering the crucible and respectively fixing the crucible on the stations of a multi-crucible platform;
s2) according to designed experimental conditions, controlling an air-cooled composite molecular pump and a direct-connected mechanical pump through a PLC (programmable logic controller) control device, and communicating an air inlet and an air outlet with a high-pressure argon bottle to form a vacuum and atmosphere environment in a smelting chamber;
s3) controlling the multi-crucible platform to rotate anticlockwise through the PLC control device, enabling the prepared crucibles to rotate to the lower part of the electrode induction melting device in sequence, enabling the master batch supply rod to rotate and move downwards, and enabling the top end of a material rod held on the rod to enter an electrode induction melting coil;
s4) controlling power supply power through a PLC control device, heating the electrode induction melting coil, melting the material rod into liquid, converging the liquid to the conical tip position of the base metal, flowing into the crucible, and mixing with the microalloy elements in the crucible; the quantitative control of the master batch is completed through the feedback of the weight sensor;
s5) after the quantitative allocation of the master batch is finished, the PLC control device controls the electromagnetic induction heating device again, the crucible lifting rod finishes the lifting action under the instruction, and the crucibles on the platform are all sent into the electromagnetic induction heating coil;
s6) controlling power supply power through a PLC control device, electrifying an electromagnetic induction heating coil, starting alloy smelting, obtaining a batch of multi-component and light-weight ingots under the same experimental conditions after the smelting is finished, reheating through the electromagnetic induction heating coil according to experimental requirements, and carrying out a homogenization heat treatment process to achieve high-flux preparation of metal material samples.
9. The method of claim 8, wherein the electrode induction melting coil of the melting system is helical with a coil tip diameter Dx1Bottom diameter of Dx2The electromagnetic induction heating coil is cylindrical, and the diameter of the coil is Dx3。
10. A method according to claim 9, wherein the diameter D of the charge barb<Dx1The length of the bar is 50 mm-800 mm; the diameter D of the crucibleg<Dx3。
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| CN112593101A (en) * | 2020-12-15 | 2021-04-02 | 江苏威拉里新材料科技有限公司 | High-temperature-resistant nickel-based alloy raw material processing and processing technology |
| CN113118448A (en) * | 2021-04-12 | 2021-07-16 | 杭州泛索能超声科技有限公司 | Novel rotatory supersound metal powder process equipment |
| CN113234956A (en) * | 2021-05-14 | 2021-08-10 | 中铝沈阳有色金属加工有限公司 | Vacuum casting method for large-tonnage chromium-zirconium-copper cast ingot |
| CN113834328A (en) * | 2021-11-26 | 2021-12-24 | 北京煜鼎增材制造研究院有限公司 | Multifunctional high-energy beam micro-area metallurgy smelting furnace and metal material high-flux preparation system |
| CN113970242A (en) * | 2021-11-05 | 2022-01-25 | 中北大学 | High-flux aluminum alloy smelting device and method |
| CN115612877A (en) * | 2022-10-10 | 2023-01-17 | 北京航空材料研究院股份有限公司 | Method for intelligently vacuum induction smelting of high-temperature alloy master alloy |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112593101A (en) * | 2020-12-15 | 2021-04-02 | 江苏威拉里新材料科技有限公司 | High-temperature-resistant nickel-based alloy raw material processing and processing technology |
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| CN113118448A (en) * | 2021-04-12 | 2021-07-16 | 杭州泛索能超声科技有限公司 | Novel rotatory supersound metal powder process equipment |
| CN113234956A (en) * | 2021-05-14 | 2021-08-10 | 中铝沈阳有色金属加工有限公司 | Vacuum casting method for large-tonnage chromium-zirconium-copper cast ingot |
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| CN113970242B (en) * | 2021-11-05 | 2023-11-10 | 中北大学 | High-flux aluminum alloy smelting device and method |
| CN113834328A (en) * | 2021-11-26 | 2021-12-24 | 北京煜鼎增材制造研究院有限公司 | Multifunctional high-energy beam micro-area metallurgy smelting furnace and metal material high-flux preparation system |
| CN115612877A (en) * | 2022-10-10 | 2023-01-17 | 北京航空材料研究院股份有限公司 | Method for intelligently vacuum induction smelting of high-temperature alloy master alloy |
| CN115612877B (en) * | 2022-10-10 | 2023-10-27 | 北京航空材料研究院股份有限公司 | Intelligent vacuum induction melting method for high-temperature alloy master alloy |
| CN115652090A (en) * | 2022-12-28 | 2023-01-31 | 清苑县宏达金属有限公司 | Vacuum electric furnace for alloy smelting |
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